US7754094B2 - Sintered ferrite and its production method and electronic part using same - Google Patents

Sintered ferrite and its production method and electronic part using same Download PDF

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US7754094B2
US7754094B2 US10/596,784 US59678404A US7754094B2 US 7754094 B2 US7754094 B2 US 7754094B2 US 59678404 A US59678404 A US 59678404A US 7754094 B2 US7754094 B2 US 7754094B2
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magnetic flux
flux density
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ferrite
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Masahiro Takahashi
Syuichi Takano
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Proterial Ltd
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/26—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on ferrites
    • C04B35/2658—Other ferrites containing manganese or zinc, e.g. Mn-Zn ferrites
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/34—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials non-metallic substances, e.g. ferrites
    • H01F1/342—Oxides
    • H01F1/344—Ferrites, e.g. having a cubic spinel structure (X2+O)(Y23+O3), e.g. magnetite Fe3O4
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
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    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
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    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
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    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3262—Manganese oxides, manganates, rhenium oxides or oxide-forming salts thereof, e.g. MnO
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    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3262—Manganese oxides, manganates, rhenium oxides or oxide-forming salts thereof, e.g. MnO
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    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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Definitions

  • the present invention relates to a Mn—Zn sintered ferrite body having a high maximum magnetic flux density at as high temperatures as about 100° C., and an electronic part using such sintered ferrite.
  • DC-DC converters, etc. used in electric vehicles, hybrid vehicles, etc. are also operated in wide temperature ranges, so that they are required to exhibit enough performance even at 100° C. or higher. Accordingly, these in-vehicle DC-DC converters, etc. are required to be adaptable to higher temperatures and larger current.
  • Adaptability to higher temperatures and larger current is also required by choke coils constituting DC-DC converters, and their parts, magnetic cores.
  • the choke coils are required to have high inductance even when large current is supplied at high temperatures.
  • the magnetic cores are required to be usable at a frequency of several hundreds of kHz, and resistant to magnetic saturation even when large current is supplied at high temperatures.
  • Magnetic cores for choke coils, etc. are made of soft-magnetic metals such as silicon steel, amorphous alloys, soft-magnetic, fine-crystal alloys, etc., or ferrites.
  • the soft-magnetic metals have higher saturation magnetic flux densities than those of ferrites, thus resistant to magnetic saturation even when large current is supplied, they are disadvantageous in a high cost, and low resistance that makes use at high frequencies impossible.
  • the soft-magnetic ferrites can advantageously be used at high frequencies because of higher resistance than the soft-magnetic metals, in addition to a low cost.
  • Mn—Zn ferrite is suitable for large-current cores, because it has a higher saturation magnetic flux density than that of Ni—Zn ferrite.
  • conventional Mn—Zn ferrite generally comprises about 50-55% by mol of Fe 2 O 3 , and it is known that increase in the Fe 2 O 3 content leads to a higher maximum magnetic flux density.
  • the magnetic properties of ferrite generally tend to be influenced by temperatures.
  • Particularly Mn—Zn ferrite has a high maximum magnetic flux density at room temperature, but its maximum magnetic flux density decreases as the temperature is elevated.
  • the maximum magnetic flux density at a high temperature of about 100° C. is usually as low as about 75-80% of that at room temperature.
  • Such reduction of a maximum magnetic flux density leads to the deterioration of DC bias current characteristics when used in choke coils.
  • To obtain a high maximum magnetic flux density at a high temperature of about 100° C. it is necessary to compensate the reduction of a maximum magnetic flux density with temperature, by increasing the maximum magnetic flux density at room temperature, or by decreasing the reduction ratio of a maximum magnetic flux density as the temperature is elevated.
  • JP6-333726A discloses a method for producing Mn—Zn ferrite having a high maximum magnetic flux density without undesirable phases such as a wustite phase, a hematite phase, etc., by sintering a ferrite material comprising 62-68% of Fe 2 O 3 , 16-28% of MnO and 10-16% of ZnO by mol as main components, and at least one of CaO, SiO 2 , ZrO 2 and CoO as a sub-component, together with an organic binder as a reducing agent in a inert gas.
  • JP6-333726A cannot provide the resultant sintered body with a sufficient maximum magnetic flux density at room temperature, and the maximum magnetic flux density decreases largely as the temperature is elevated. Accordingly, it is difficult to produce Mn—Zn ferrite having a high maximum magnetic flux density at a high temperature of 100° C.
  • JP11-329822A discloses a sintered Mn—Zn ferrite body having a high maximum magnetic flux density particularly at a high temperature of 100° C., which comprises 60-85% by mol of iron oxide, and 0-20% by mol of zinc oxide, the balance being manganese oxide, and has as high a maximum magnetic flux density as 450 mT or more at 100° C., with a small reduction ratio of a maximum magnetic flux density with temperature.
  • sintered Mn—Zn ferrite has a density of less than 4.9 g/cm 3 , not on a sufficient level as compared with the theoretical density of 5.1-5.2 g/cm 3 .
  • the above excess-Fe composition may generate undesirable phases such as a hematite phase, etc. depending on the variations of production conditions, making it difficult to stably obtain Mn—Zn ferrite having a high maximum magnetic flux density.
  • a spinelization reaction should be accelerated and controlled more than usual Mn—Zn ferrites comprising 50-55% by mol of Fe 2 O 3 .
  • undesirable phases such as a hematite phase, etc. are easily formed in the spinelization reaction, it is difficult to achieve a high maximum magnetic flux density with good reproducibility.
  • an organic binder is added as a reducing agent, too, its amount is limited from the aspect of moldability, and because its effects are different depending on the ferrite compositions, etc., it is difficult to obtain a sintered ferrite body having a high maximum magnetic flux density with good reproducibility.
  • an object of the present invention is to provide a method for mass-producing a sintered ferrite body having a composition with much excess Fe for having a high maximum magnetic flux density, stably at a low cost.
  • Another object of the present invention is to provide a sintered ferrite body having a much higher maximum magnetic flux density than those of conventional Mn—Zn ferrites particularly at as high a temperature as 100° C.
  • a further object of the present invention is to provide an electronic part using such sintered ferrite.
  • the sintered ferrite body of the present invention preferably has a volume resistivity of 0.1 ⁇ m or more. This enables the sintered ferrite body to have the same insulation as that of general Mn—Zn ferrites, with reduced core loss and a high maximum magnetic flux density.
  • the sintered ferrite body of the present invention preferably has a temperature at which its core loss is minimum (minimum-core-loss temperature) of 80° C.-120° C., to provide a ferrite core with a high maximum magnetic flux density, and make it suitable for use at as high a temperature as about 100° C.
  • minimum-core-loss temperature 80° C.-120° C.
  • the electronic part of the present invention comprising a magnetic core formed by the above sintered ferrite body, and winding.
  • the method of the present invention for producing the above sintered ferrite body comprises a step of adding a binder to ferrite powder, a molding step, a binder-removing step, and a sintering step; the ferrite powder having a spinelization ratio S of 10-60%; the amount V (% by weight) of the binder added being in a range of 1.3 ⁇ 0.02S ⁇ V ⁇ 2.3 ⁇ 0.02S, assuming that the total amount of the ferrite powder and the binder is 100% by weight; and the oxygen concentration in the atmosphere from the binder-removing step to the completion of the sintering step being 0.1% or less by volume.
  • This method provides a sintered ferrite body having a composition with much excess Fe and a properly controlled amount of Fe 2+ for having a high maximum magnetic flux density.
  • the spinelization ratio of ferrite powder is preferably 10-40%. This achieves the mass-production of a sintered ferrite body having a high maximum magnetic flux density, even when a large amount of a binder is added to achieve high moldability.
  • the ferrite powder preferably has a specific surface area of 3000-7000 m 2 /kg. This provides the sintered ferrite with a high density and a high maximum magnetic flux density.
  • the main composition of the sintered ferrite body of the present invention preferably comprises 68-75% by mol of Fe 2 O 3 , and 3-12% by mol of ZnO, the balance being manganese oxide. This provides the sintered ferrite with a high maximum magnetic flux density even at high temperatures.
  • the sintered ferrite body of the present invention preferably contains 0.02-0.3% by weight (calculated as CaCO 3 ) of Ca, and 0.003-0.015% by weight (calculated as SiO 2 ) of Si, as sub-components, per 100% by weight of the main composition. This provides the sintered ferrite with high maximum magnetic flux density and volume resistivity.
  • the sintered ferrite body of the present invention has a dramatically improved maximum magnetic flux density, which is particularly high at as high a temperature as 100° C.
  • Electronic parts such as choke coils, etc. using such sintered ferrite can be used with large current at as high a temperature as about 100° C.
  • the method of the present invention can stably produce a sintered ferrite body having a high maximum magnetic flux density without generating undesirable phases, even with a composition with much excess Fe, which is conventionally likely to generate undesirable phases under varied production conditions.
  • FIG. 1 is a graph showing the relation between the spinelization ratio of ferrite powder and the amount of a binder added.
  • FIG. 2 is a graph showing the relation between the Fe content in the sintered ferrite body and the percentage R of Fe 2+ , and a maximum magnetic flux density at 100° C.
  • FIG. 3 is a graph showing the DC bias current characteristics of Samples 51 and 52.
  • FIG. 4 is a perspective view showing the shape of a core for measuring the DC bias current characteristics.
  • the sintered ferrite body of the present invention can be produced by powder metallurgy methods usually used for the production of Mn—Zn ferrites. Namely, Fe 2 O 3 , manganese oxide (for instance, Mn 3 O 4 ) and ZnO as main starting materials are mixed by a ball mill, etc., calcined, and then pulverized by a ball mill, etc. The resultant ferrite powder is mixed with a binder, etc., granulated by a spray drier, etc., and molded. The resultant green body is sintered.
  • the sintered ferrite body of the present invention has a main composition comprising 63-80% by mol of Fe 2 O 3 , and 3-15% by mol of ZnO, the balance being manganese oxide. With such a main composition, the resultant sintered ferrite body has a maximum magnetic flux density of 520 mT or more at 100° C. in a magnetic field of 1000 A/m, extremely higher than those of conventional sintered ferrites.
  • the maximum magnetic flux density drastically decreases as the temperature is elevated. Even though it is high at room temperature (20° C.), the maximum magnetic flux density of 520 mT or more cannot be obtained at 100° C.
  • a hematite phase Fe 2 O 3
  • an undesirable phase tends to remain, resulting in the deterioration of soft magnetic properties such as permeability, etc. and decrease in the maximum magnetic flux density, also failing to achieve the maximum magnetic flux density of 520 mT or more at 100° C.
  • the ZnO content is outside a range of 3-15% by mol, the sintered ferrite body has a reduced maximum magnetic flux density, which cannot be 520 mT or more at 100° C.
  • the Fe 2 O 3 content is preferably 68-75% by mol.
  • the sintered ferrite body can have extremely as high a maximum magnetic flux density as 540 mT or more at 100° C. in a magnetic field of 1000 A/m.
  • the sintered ferrite body of the present invention has a higher maximum magnetic flux density than those of the conventional Mn—Zn ferrites even at temperatures higher than 100° C.
  • the sintered ferrite body containing 75-80% by mol of Fe 2 O 3 has a maximum magnetic flux density of 500 mT or more even at 150° C., it is suitable for applications such as automobiles, etc. requiring high heat resistance.
  • the sintered ferrite body has a Curie temperature of 410° C. or higher.
  • the higher the Curie temperature the smaller the change of the maximum magnetic flux density with temperature.
  • the Curie temperature is 410° C. or higher, the ratio of a maximum magnetic flux density at 100° C. to that at 20° C. (reduction ratio of a maximum magnetic flux density from 20° C. to 100° C.) is as small as 10% or less.
  • the maximum magnetic flux density of the ferrite becomes extremely low by heat generated by surrounding electronic parts.
  • the sintered ferrite body of the present invention suffering little change of a maximum magnetic flux density with temperature is not susceptible to heat generated by surrounding electronic parts, electronic equipments comprising it are easily designed.
  • the sintered ferrite body of the present invention When containing 0.02-0.3% by weight (calculated as CaCO 3 ) of Ca, and 0.003-0.015% by weight (calculated as SiO 2 ) of Si as sub-components, the sintered ferrite body of the present invention has high volume resistivity and little core loss (particularly eddy current loss).
  • Ca is less than 0.02% by weight (calculated as CaCO 3 )
  • the volume resistivity is not sufficiently improved.
  • Ca exceeds 0.3% by weight the sinterability decreases, resulting in a sintered body with reduced density and maximum magnetic flux density.
  • Si is less than 0.003% by weight (calculated as SiO 2 )
  • the volume resistivity is not sufficiently improved.
  • Si exceeds 0.015% by weight coarse grains are formed in the sintered body structure, resulting in reduced magnetic properties and volume resistivity.
  • the inclusion of the sub-components in the above ranges provides a high-maximum-magnetic-flux-density sintered ferrite body having volume resistivity of 0.1 ⁇ m or more on the same level as those of usual Mn—Zn ferrites, even with a composition having much excess Fe and an extremely large amount of Fe 2+ .
  • the use of sintered ferrite bodies having such high maximum magnetic flux density and low volume resistivity can avoid the design of electronic parts from becoming complicated.
  • Mn as a main component may be substituted by at least one selected from the group consisting of Co, Ni, Cu, Ti, Sn and Li, in an amount of 7% by mol or less per 100% by mol of the entire main components.
  • the sintered ferrite body of the present invention may contain a compound (oxide, etc.) of at least one selected from the group consisting of Nb, Zr, V, Ta, Bi, W, Mo, Al and rare earth metals (including Y), in an amount of 0.2% by weight or less per 100% by weight of the entire sintered body.
  • the core loss causing the heat generation of a sintered ferrite body is preferably as small as possible, and it is preferably 1700 kW/m 3 or less at 50 kHz and 150 mT in such applications as DC-DC converters, etc.
  • the minimum-core-loss temperature is generally set higher than the temperature of using the sintered ferrite body. With the minimum-core-loss temperature of 80° C.-120° C., the thermal runaway can be prevented even though the temperature of the electronic equipment becomes higher than room temperature.
  • the minimum-core-loss temperature may be controlled by adjusting the compositions of the main components, etc. For instance, with a composition of 68-72% by mol of Fe 2 O 3 , and 3-12% by mol of ZnO, the balance being manganese oxide, the minimum-core-loss temperature is in a range of 80-120° C.
  • the sintered ferrite body of the present invention has a density of 4.9 g/cm 3 or more.
  • the density is less than 4.9 g/cm 3
  • the sintered ferrite body with as excessively high Fe 2 O 3 content as 63-80% by mol has an extremely low maximum magnetic flux density, which cannot be 520 mT or more at 100° C.
  • the sintered body preferably has a density of 4.95 g/cm 3 or more.
  • the ratio R (%) of Fe 2+ to the total amount of Fe in the sintered ferrite body, and R cal determined by the formula of R cal [200(X ⁇ 50)]/(3X) meet the condition of R cal ⁇ 2.0 ⁇ R ⁇ R cal +0.3.
  • Fe 2+ has positive magnetic anisotropy, opposite to ions of the main components such as Fe 3+ , etc., with different temperature dependency, the existence of Fe 2+ affects the temperature characteristics of initial permeability, etc. (for instance, so-called secondary peak temperature shift). Also, the existence of Fe 2+ affects the electric resistance of ferrite.
  • the inventors have found that the amount of Fe 2+ has large influence on the maximum magnetic flux density as well as on the temperature characteristics of initial permeability.
  • the percentage of Fe 2+ is not necessarily equal to R cal .
  • the controlling of the ratio R (%) of Fe 2+ which is variable depending on production conditions, in a range of R cal ⁇ 2.0 ⁇ R ⁇ R cal +0.3 provides the sintered body with a remarkably higher maximum magnetic flux density than those of conventional sintered bodies.
  • the amount of Fe 2+ in the sintered ferrite body is determined by dissolving the sintered body in strong phosphoric acid, and titrating it with a standard solution of potassium dichromate using sodium diphenylamine-4-sulfonate as an indicator.
  • the total amount of Fe is determined by decomposing the sintered body with hydrochloric acid, oxidizing Fe 2+ in Fe (Fe 2+ , Fe 3+ ) entirely to Fe 3+ with hydrogen peroxide, reducing Fe 3+ to Fe 2+ with stannous chloride, and then titrating it with a standard solution of potassium dichromate.
  • the spinelization ratio of ferrite powder S to be molded is 10-60%; the amount V (% by weight) of the binder added is in a range of 1.3 ⁇ 0.02S ⁇ V ⁇ 2.3 ⁇ 0.02S, assuming that the total of the ferrite powder and the binder is 100% by weight; and the oxygen concentration in the atmosphere from the binder-removing step to the completion of the sintering step is 0.1% or less by volume.
  • the spinelization ratio is represented by a percentage of I 311 /(I 311 +I 104 ), wherein I 311 represents the intensity of a 311-peak of a spinel phase (maximum-intensity peak of the spinel phase), and I 104 represents the intensity of a 104-peak of a hematite phase (maximum-intensity peak of the hematite phase), in a powder X-ray diffraction pattern.
  • the amount of the binder added is represented by the percentage by weight of the binder per the total of the ferrite powder and the binder.
  • the spinelization ratio of ferrite powder to be molded is less than 10%, large sintering deformation occurs, resulting in a sintered ferrite body with low dimensional accuracy, and a hematite phase tends to remain as an undesirable phase because of insufficient sinterability and spinelization, resulting in a sintered ferrite body with a low maximum magnetic flux density.
  • the spinelization ratio exceeds 60%, a wustite phase, an undesirable phase, tends to be formed, and the amount of a binder suitable for obtaining a high maximum magnetic flux density becomes extremely small, resulting in difficulty in suppressing undesirable phases and achieving good moldability.
  • the preferred spinelization ratio is 10-40%.
  • a larger amount of a binder is desirable, although too much a binder causes excess reduction.
  • the spinelization ratio is 10-40%, a sintered ferrite body having a high maximum magnetic flux density can be obtained even though 1.5% or more by weight of a binder is added.
  • the amount of the binder added is preferably 1.0-1.8% by weight.
  • Organic binders are preferable in the present invention, and for instance, polyvinyl alcohol (PVA), etc. may be used.
  • the atmosphere gas is an inert gas, and it is preferably a nitrogen gas for cost reduction.
  • the use of pure nitrogen makes the control of an oxygen concentration unnecessary.
  • the use of a reducing gas such as H 2 , CO, hydrocarbons, etc. accelerates a spinelization reaction and improves sinterability.
  • the term “from the binder-removing step to the completion of the sintering step” means a period from a time at which the binder starts to evaporate by heating to a time at which the sintering-temperature-keeping step ends.
  • the binder-removing step need not be an independent step, but the binder evaporates in the course of temperature elevation from room temperature to the sintering temperature. Cooling after the sintering-temperature-keeping step may be conducted while being controlled to an equilibrium oxygen partial pressure, and it is preferably conducted in a nitrogen atmosphere for the purpose of simplification.
  • the ferrite powder to be molded is usually obtained by pulverization after calcining, but the calcined ferrite powder has a spinelization ratio at several tens of percentage.
  • the spinelization ratio increases by an oxygen-removing reaction (reduction reaction), so that the spinelization ratio becomes 100% ideally after the completion of sintering.
  • the ratio of Fe 2+ varies depending on the reduction reaction. Because the sintered ferrite body of the present invention contains much excess Fe as compared with the conventional Mn—Zn ferrites, the sintering atmosphere preferably has a low oxygen concentration to accelerate the oxygen-removing reaction.
  • JP11-329822A describes that calcining is preferably conducted in nitrogen, and JP6-333726A describes that the spinelization ratio of the calcined ferrite powder should be 60-90%.
  • These are considered preferable to proceed a spinelization reaction before sintering ferrite powder with excess Fe, from which a large amount of oxygen should be released, but the oxygen-removing reaction is largely affected not only by an oxygen concentration in the sintering atmosphere, but also by the amount of a binder such as PVA, etc. This is because the thermal decomposition of a binder comprising C and H as main constituents generates reducing gases, which accelerate the oxygen-removing reaction.
  • the binder-removing step When the binder-removing step is conducted in the air, the binder is reacted with oxygen in the air, failing to accelerate the oxygen-removing reaction, but the oxygen-removing reaction is remarkably accelerated by carrying out the binder-removing step and the sintering step in a low-oxygen atmosphere such as nitrogen, etc.
  • the percentage of Fe 2+ varies depending on the main component composition, calcining conditions, etc., it has been difficult to stably produce a sintered ferrite body with much excess Fe.
  • the percentage R of Fe 2+ can be in a range of R cal ⁇ 2.0 ⁇ R ⁇ R cal +0.3, resulting in a sintered ferrite body with a high maximum magnetic flux density.
  • the sintering temperature is preferably in a range of 1150° C.-1250° C.
  • the sintering temperature is lower than 1150° C., the sintered body tends to have a low density and contain a hematite phase, an undesirable phase, resulting in a reduced maximum magnetic flux density.
  • the sintering temperature exceeds 1250° C., coarse grains abnormally grow in the sintered body, resulting in reduced magnetic properties such as maximum magnetic flux density, etc.
  • the spinelization ratio of ferrite powder can be controlled by the ferrite powder composition and the calcining atmosphere and temperature of ferrite powder, etc. Under the same calcining conditions, the more excess Fe in the ferrite powder used, the lower spinelization ratio. Also, the smaller the oxygen content in the calcining atmosphere, the higher the spinelization ratio. To achieve a spinelization ratio of 10-60%, the calcining atmosphere may be from nitrogen to the air, but calcining in the air is preferable from the aspect of mass-productivity and cost. Because too high a calcining temperature produces coarse calcined ferrite powder, the calcining temperature is preferably 800° C.-950° C.
  • the ferrite powder to be molded need only have a spinelization ratio of 10-60%, and may be obtained not only by calcining (solid-phase reaction of mixed powder), but also by hydrothermal synthesis, etc.
  • the maximum magnetic flux density of the sintered ferrite body depends on the amount of Fe 2+ and the density of the sintered body.
  • the composition with much excess Fe can provide a high maximum magnetic flux density, although the resultant sintered body tends to have a low density.
  • a higher sintering temperature generally provides higher density, but the inventors have found that when ferrite powder with much excess Fe is sintered in an atmosphere having an oxygen concentration of 0.1% or less by volume, a sintered body with improved density cannot be obtained even by elevating the sintering temperature.
  • ferrite powder to be molded has a specific surface area in a range of 3000-7000 m 2 /kg, a sintered ferrite body having a uniform structure with as high density as 4.9 g/cm 3 or more can be obtained even if the Fe 2 O 3 content is as much excess as 63-80% by mol.
  • the specific surface area of ferrite powder When the specific surface area of ferrite powder is less than 3000 m 2 /kg, the sintered body does not have a sufficiently increased density. When the specific surface area exceeds 7000 m 2 /kg, the handling of ferrite powder becomes difficult, and its pulverization needs much time, resulting in reduced productivity. Also, when extremely fine ferrite powder with a specific surface area exceeding 7000 m 2 /kg is used, coarse grains abnormally grow in the sintered ferrite, resulting in the sintered body with reduced strength and deteriorated magnetic properties.
  • the ferrite powder having a specific surface area of 3000-7000 m 2 /kg generally has an average particle size d50 of 0.9-1.8 ⁇ m.
  • the average particle size can be measured by an air permeation method, but the average particle size measured by the air permeation method tends to be smaller than that measured by a laser diffraction method.
  • the ferrite powder more preferably has a specific surface area of 4000-7000 m 2 /kg.
  • the specific surface area of the ferrite powder can be controlled by pulverization conditions such as pulverization time, etc. Incidentally, the specific surface area is measured by a BET method.
  • Fe 2 O 3 powder, Mn 3 O 4 powder and ZnO powder weighed to have the composition shown in Table 1 were mixed by wet-ball-milling for 4 hours, dried, and then calcined at 900° C. for 1.5 hours in nitrogen.
  • Sample 17 was calcined at 850° C. for 1.5 hours in the air.
  • Each of the resultant calcined powders was mixed with 0.08% by weight (calculated as CaCO 3 ) of Ca, 0.006% by weight (calculated as SiO 2 ) of Si, and 0.03% by weight (calculated as Ta 2 O 5 ) of Ta, and pulverized by wet-ball-milling for 15-20 hours to have a specific surface area in a range of 4000-7000 m 2 /kg. Specifically, the surface area was 4110 m 2 /kg in Sample 9.
  • Each pulverized ferrite powder was mixed with PVA as a binder in the amount shown in Table 1, dried, and then granulated. The granulated ferrite powder was compression-molded to a ring shape, heated to 1175° C.
  • a high-purity nitrogen gas having purity of 99.99% or more was used as an atmosphere gas.
  • the resultant ring-shaped sintered body having an outer diameter of 25 mm, an inner diameter of 15 mm, and a height of 5 mm was measured with respect to initial permeability ⁇ i at 10 kHz, and maximum magnetic flux densities (Bm 20° C. , Bm 100° C. , BM 150° C. ) at 20° C., 100° C. and 150° C., respectively, in a magnetic field of 1000 A/m.
  • the reduction ratio of a maximum magnetic flux density [100 ⁇ (Bm 20° C. ⁇ Bm 100° C. )/Bm 20° C. ] was calculated when heated from 20° C. to 100° C.
  • a spinelization ratio was measured on each ferrite powder, and a density ds, volume resistivity ⁇ , a grain size, a Curie temperature Tc, the presence of an undesirable phase, and the percentage R of Fe 2+ in the total Fe content were measured on each sintered body.
  • the density of each sintered body was measured by a water displacement method.
  • the volume resistivity of each sintered body was measured by a two-terminal method with a conductive paste applied to a cut surface of a ring-shaped sample.
  • the grain size of each sintered body was determined by taking an optical photomicrograph (1000 times) of a sample mirror-polished and etched by hydrochloric acid, counting the number of grains existing on a 10-cm-long line (corresponding to 100 ⁇ m) drawn on the optical photomicrograph, and dividing 100 ⁇ m by the number of grains.
  • the presence of an undesirable phase in the sintered body was confirmed by observation by SEM and an optical microscope at 1000 times, and X-ray diffraction.
  • the core loss was measured under the conditions of 50 kHz and 150 mT. The results are shown in Table 1.
  • the sintered Mn—Zn ferrite had a Curie temperature of 410° C. or higher, as high a maximum magnetic flux density as 520 mT or more at 100° C., and as small a reduction ratio of a maximum magnetic flux density with temperature as 10% or less from 20° C. to 100° C. Further, with a composition comprising 68-75% by mol of Fe 2 O 3 and 3-12% by mol of ZnO, the balance being manganese oxide, the maximum magnetic flux density was as extremely high as 540 mT or more at 100° C.
  • the core loss was measured.
  • the results are shown in Table 2.
  • the sintered ferrite bodies within the composition range of the present invention had high maximum magnetic flux densities, and as small core losses as 1700 kW/m 3 or less at 50 kHz and 150 mT.
  • the main components of the sintered ferrite body were within the composition ranges of 68-72% by mol of Fe 2 O 3 , and 3-12% by mol of ZnO, the balance being manganese oxide
  • the minimum-core-loss temperature was in a range of 80-120° C., making the sintered bodies suitable for use near 100° C.
  • the Fe 2 O 3 content was 75% or more by mol, heat generation was observed during the measurement of a core loss.
  • Fe 2 O 3 powder, ZnO powder and Mn 3 O 4 powder were weighed to a composition comprising 70% by mol of Fe 2 O 3 , and 10% by mol of ZnO, the balance being MnO, mixed by wet-ball-milling for 4 hours, dried, and then calcined at 900° C. for 1.5 hours in nitrogen.
  • the resultant calcined powder was mixed with CaCO 3 powder and SiO 2 powder in the amounts shown in Table 3, pulverized by wet-ball-milling for 20 hours, further mixed with 1.0% by weight of PVA as a binder, dried, and then granulated.
  • the granulated powder was compression-molded to a ring shape, heated to 1175° C.
  • the spinelization ratio of ferrite powder to be molded was 42%.
  • the resultant ring-shaped sintered body having an outer diameter of 25 mm, an inner diameter of 15 mm and a height of 5 mm was measured with respect to initial permeability ⁇ i at 10 kHz, and a maximum magnetic flux density at 20° C. and 100° C. in a magnetic field of 1000 A/m.
  • Fe 2 O 3 powder, Mn 3 O 4 powder and ZnO powder were weighed to the composition shown in Table 4, mixed by wet-ball-milling for 4 hours, dried, and then calcined at 900° C. for 1.5 hours in nitrogen. Samples 41 and 42 were separately calcined at 850° C. for 1.5 hours in the air. Each calcined powder was mixed with 0.08% by weight of CaCO 3 powder, 0.006% by weight of SiO 2 powder, and 0.03% by weight of Ta 2 O 5 powder, and pulverized by wet-ball-milling for such controlled pulverization time as to provide a specific surface area of 4000-7000 m 2 /kg.
  • the resultant pulverized powder was mixed with PVA as a binder in the amount shown in Table 4, dried, and then granulated.
  • the granulated powder was compression-molded to a ring shape, heated to 1175° C. at a temperature-elevating speed of 150° C./hour, kept at 1175° C. for 8 hours for sintering.
  • a nitrogen atmosphere was used from the binder-removing step to the completion of the sintering step and during the subsequent cooling step, like in Example 1.
  • the resultant ring-shaped sintered body having an outer diameter of 25 mm, an inner diameter of 15 mm and a height of 5 mm was measured with respect to initial permeability ⁇ i at 10 kHz, and a maximum magnetic flux density at 20° C.
  • Fe 2 O 3 powder, ZnO powder and Mn 3 O 4 powder were weighed such that Fe 2 O 3 was 70% by mol, and ZnO was 10% by mol, the balance being MnO, mixed by wet-ball-milling for 4 hours, dried, and then calcined at 900° C. for 1.5 hours in nitrogen.
  • the resultant calcined powder was mixed with 0.08% by weight (calculated as CaCO 3 ) of Ca, 0.006% by weight (calculated as SiO 2 ) of Si, and 0.03% by weight (calculated as Ta 2 O 5 ) of Ta, pulverized by wet-ball-milling for 20 hours, further mixed with 1.0% by weight of PVA as a binder, dried, and then granulated.
  • the granulated powder was compression-molded to a ring shape, heated to 1175° C. at a temperature-elevating speed of 150° C./hour, and kept at 1175° C. for 8 hours for sintering.
  • An atmosphere having the oxygen concentration shown in Table 5 was used from the binder-removing step to the completion of the sintering step, and a nitrogen atmosphere was used in the subsequent cooling step.
  • the spinelization ratio of ferrite powder to be molded was 42%.
  • the resultant ring-shaped sintered body having an outer diameter of 25 mm, an inner diameter of 15 mm and a height of 5 mm was measured with respect to density ds, initial permeability ⁇ i at 10 kHz, and a maximum magnetic flux density at 20° C. and 100° C. in a magnetic field of 1000 A/m. The results are shown in Table 5.
  • Fe 2 O 3 powder, ZnO powder and Mn 3 O 4 powder were weighed such that Fe 2 O 3 was 70% by mol, and ZnO was 10% by mol, the balance being MnO, mixed by wet-ball-milling for 4 hours, dried, and then calcined at 850° C. for 1.5 hours in the air.
  • the resultant calcined powder was mixed with 0.08% by weight (calculated as CaCO 3 ) of Ca, 0.006% by weight (calculated as SiO 2 ) of Si, and 0.03% by weight (calculated as Ta 2 O 5 ) of Ta, pulverized by wet-ball-milling for the pulverization time shown in Table 6, further mixed with 1.5% by weight of PVA as a binder, dried, and then granulated.
  • the granulated powder was compression-molded to a ring shape, heated to 1175° C. at a temperature-elevating speed of 150° C./hour, and kept at 1175° C. for 8 hours for sintering.
  • a nitrogen atmosphere was used from the binder-removing step to the completion of the sintering step and during the subsequent cooling step, like in Example 1.
  • the spinelization ratio of ferrite powder to be molded was 11%.
  • the resultant ring-shaped sintered body having an outer diameter of 25 mm, an inner diameter of 15 mm and a height of 5 mm was measured with respect to density ds, initial permeability ⁇ i at 10 kHz, and a maximum magnetic flux density at 20° C. and 100° C. in a magnetic field of 1000 A/m.
  • the specific surface area S of the ferrite powder was measured by a BET method.
  • the average particle size d50 was determined from a particle size distribution measured by a laser diffraction-type particle size distribution meter available from Horiba, Ltd. The results are shown in Table 6.
  • the resultant sintered body had high density and a high maximum magnetic flux density. Particularly with the specific surface area of 4000-7000 m 2 /kg, higher density and maximum magnetic flux density were obtained.
  • Fe 2 O 3 powder, ZnO powder and Mn 3 O 4 powder were weighed such that Fe 2 O 3 was 70% by mol, and ZnO was 10% by mol, the balance being MnO, mixed by wet-ball-milling for 4 hours, dried, and then calcined at 950° C. for 1.5 hours in nitrogen.
  • the resultant calcined powder was mixed with 0.08% by weight (calculated as CaCO 3 ) of Ca, 0.006% by weight (calculated as SiO 2 ) of Si, and 0.03% by weight (calculated as Ta 2 O 5 ) of Ta, pulverized by wet-ball-milling for 10 hours, further mixed with 1.0% by weight of PVA as a binder, dried, and then granulated.
  • the granulated powder was compression-molded to a cylindrical shape, heated to 1175° C. at a temperature-elevating speed of 150° C./hour, and kept at 1175° C. for 8 hours for sintering.
  • a nitrogen atmosphere was used from the binder-removing step to the completion of the sintering step and during the subsequent cooling step, like in Example 1.
  • the spinelization ratio of ferrite powder to be molded was 46%.
  • the resultant cylindrical sintered body having an outer diameter of 8.5 mm and a height of 4 mm (Sample 51) was machined to a drum-shaped core shown in FIG. 4 .
  • a 2-UEW wire of 0.25 mm in diameter was wound around this drum-shaped core in 50 turns.
  • DC bias current characteristics were measured at 20° C. and 100° C. under the conditions of a frequency of 100 kHz and current of 1 mA. The results are shown in FIG. 3 .
  • a sintered ferrite body (Sample 52) having a composition comprising 53% by mol of Fe 2 O 3 , 7% by mol of ZnO and 40% by mol of MnO was machined to the same drum-shaped core as in Sample 51.
  • a 2-UEW wire of 0.25 mm in diameter was wound around this drum-shaped core in 47 turns.
  • the DC bias current characteristics were measured under the same conditions as in Sample 51. The results are shown in FIG. 3 .
  • Table 7 shows the compositions and maximum magnetic flux densities of Samples 51 and 52. As is clear from FIG. 3 , Sample 51 within the range of the present invention had better DC bias current characteristics than those of Sample 52 outside the range of the present invention.
  • the sintered ferrite body of the present invention has a high maximum magnetic flux density, it can be used for parts such as cores for DC-DC converters, etc. Particularly because it has an extremely higher maximum magnetic flux density than those of conventional Mn—Zn ferrites at a high temperature of 100° C., it is suitable for coil parts in electronic apparatuses used at high temperatures. Such sintered ferrite body can be stably produced by the method of the present invention at a low cost.

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EP1702903A4 (en) 2011-04-27
ATE544736T1 (de) 2012-02-15
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JP2005187232A (ja) 2005-07-14
US20070290162A1 (en) 2007-12-20

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